Classifications

• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F1/00—Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
  • G03F1/50—Mask blanks not covered by G03F1/20 - G03F1/34; Preparation thereof
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F7/004—Photosensitive materials
  • G03F7/09—Photosensitive materials characterised by structural details, e.g. supports, auxiliary layers
  • G03F7/092—Photosensitive materials characterised by structural details, e.g. supports, auxiliary layers characterised by backside coating or layers, by lubricating-slip layers or means, by oxygen barrier layers or by stripping-release layers or means
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F5/00—Screening processes; Screens therefor
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F5/00—Screening processes; Screens therefor
  • G03F5/20—Screening processes; Screens therefor using screens for gravure printing
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F7/20—Exposure; Apparatus therefor
  • G03F7/2002—Exposure; Apparatus therefor with visible light or UV light, through an original having an opaque pattern on a transparent support, e.g. film printing, projection printing; by reflection of visible or UV light from an original such as a printed image
  • G03F7/2014—Contact or film exposure of light sensitive plates such as lithographic plates or circuit boards, e.g. in a vacuum frame
  • G03F7/2016—Contact mask being integral part of the photosensitive element and subject to destructive removal during post-exposure processing
  • G03F7/202—Masking pattern being obtained by thermal means, e.g. laser ablation

Definitions

• the present invention relates generally to methods for improving print performance of relief image printing elements for optimal printing and higher solid ink density.
• Flexographic printing plates are relief plates with image elements raised above open areas. Generally, the plate is somewhat soft, and flexible enough to wrap around a printing cylinder, and durable enough to print over a million copies. Such plates offer a number of advantages to the printer, based chiefly on their durability and the ease with which they can be made.
• Flexography is commonly used for high-volume runs. Flexography is employed for printing on a variety of substrates such as paper, paperboard stock, corrugated board, films, foils and laminates. Newspapers and grocery bags are prominent examples. Coarse surfaces and stretch films can be economically printed only by means of flexography. Furthermore, due to product competition, the market requirements on the printing quality of the images on the packaging can be very stringent.
• a typical flexographic printing plate as delivered by its manufacturer is a multilayered article made of, in order, a backing, or support layer; one or more unexposed photocurable layers; optionally a protective layer or slip film; and often a protective cover sheet.
• the support sheet or backing layer lends support to the plate.
• the support sheet, or backing layer can be formed from a transparent or opaque material such as paper, cellulose film, plastic, or metal.
• Preferred materials include sheets made from synthetic polymeric materials such as polyesters, polystyrene, polyolefins, poSyamides, and the like.
• One widely used support layer is a flexible film of polyethylene terephthalate.
• the photocurable layer(s) can include any of the known photopolymers, monomers, initiators, reactive or non-reactive diluents, fillers, and dyes.
• photocurable refers to a composition which undergoes polymerization, cross-linking, or any other curing or hardening reaction in response to actinic radiation with the result that the unexposed portions of the material can he selectively separated and removed from the exposed (cured) portions to form a three-dimensional or relief pattern of cured material
• Exemplary photocurable materials are disclosed in European Patent Application Nos. 0 456 336 A2 and 0 640 878 Al to Goss, et al., British Patent No. 1,366,769, U.S. Pat. No.
• Photocurable materials generally cross-link .(cure) and harden through radical polymerization in at least some actinic wavelength region.
• actinic radiation is radiation capable of polymerizing, crosslinking or curing the photocurable layer.
• Actinic radiation includes, for example, amplified (e.g., laser) and non-amplified light, particularly in the UV and violet wavelength regions.
• amplified e.g., laser
• non-amplified light particularly in the UV and violet wavelength regions.
• One commonly used source of actimc radiation is a mercury arc lamp, although other sources are generally known to those skilled in the art.
• the slip film is a thin layer, which protects the photopolymer from dust and increases its ease of handling.
• the slip film In a conventional ("analog") plate making process, the slip film is transparent to UV light, and the printer peels the cover sheet off the printing plate blank, and places a negative on top of the slip film layer. The plate and negative are then subjected to flood-exposure by UV light through the negative. The areas exposed to the light cure, or harden, and the unexposed areas are removed (developed) to create the relief image on the printing plate.
• a laser is guided by an image stored in an electronic data file, and is used to create an in situ negative in a digital (i.e., laser ablatable) masking layer, which is generally a slip film which has been modified to include a radiation opaque material. Portions of the laser ablatable layer are then ablated by exposing the masking layer to laser radiation at a selected wavelength and power of the laser. Examples of laser ablatable layers are disclosed, for example, in U.S. Pat. No. 5,925,500 to Yang, et al., and U.S. Pat. Nos. 5,262,275 and 6,238,837 to Fan, the subject matter of each of which is herein incorporated by reference in its entirety.
• the photosensitive printing element After imaging, the photosensitive printing element is developed to remove the unpolymerized portions of the layer of photocurable material and reveal the crosslmked relief image in the cured photosensitive printing element.
• Typical methods of development include washing with various solvents or water, often with a brush.
• Other possibilities for development include the use of an air knife or heat plus a blotter (i.e., thermal development).
• Thermal development processes work by processing photopolyrner printing plates using heat; the differential melting temperature between cured and uncured photopolyrner is used to develop the latent image.
• the resulting surface after development, has a relief pattern that reproduces the image to be printed and which typically includes both solid areas and patterned areas comprising a plurality of relief dots.
• the relief image printing element may be mounted on a press and printing commenced.
• the f!exograpbic printing plate is mounted on a printing cylinder and the material to be printed, which is typically supplied as a continuous web, is placed between the printing roll and a backing roll.
• the flexographic printing plate is brought against the material with. sufficient pressure to allow contact between the relief image on the plate and the material printed.
• an ink fountain pan supplies ink to a metering roll.
• a doctor blade may also be used to wipe off excess ink from the metering roll to assist in controlling the amount of ink that is on the metering roll.
• the relief areas in the flexographic plate carry ink in a uniform layer and in predictable amounts.
• One means of controlling the amount of ink applied to the printing plate uses a special ink metering roll, known as an "anilox" roll, which has on its surface a plurality of ink metering cells. These cells are small indentations arrayed in regular patterns of a predetermined frequency and of uniform depth and shape which are typically created by engraving the cylinder face using a mechanical process or by laser; the amount of ink deli vered by the anilox roll is controlled by the screen size of the cells.
• ink is transferred from the ink well onto the anilox metering roll, filling the cells.
• the optional wiper blade wipes off excess ink from the roll surface leaving only the cells filled.
• the ink from the cells is then transferred onto the flexographic plate relief areas as the anilox roll and the flexographic plate rotate in contact with one another.
• Solid areas are defined as areas completely covered by ink having the highest, density the ink can produce on a given material
• gray areas are defined as image areas where the appearance of the printed image is of a density intermediate to pure white (total absence of ink) and solid.
• Gray areas are produced by the half-toning process described herein, in which a plurality of relief surface areas per unit area of progressively larger surface area are used to produce the illusion of different density printing. These relief areas are commonly referred to as "halftone dots.” ; Ifi addition, flexographic printing is what is known as a "binary system,” meaning that it either prints or it does not.
• gray tones are reproduced by printing a plurality of minute solid dots per unit area and varying either the frequency of the dots per unit area or the size of the dots per unit area or both.
• these halftone dots are relief areas having their surface at the top surface of the plate.
• the plate in the area surrounding the dot has been etched to a depth which except for the darkest areas reaches to a floor.
• the height of the halftone dot is the distance of the surface of the dot (and plate surface as well) to the floor, which can be referred to as the "halftone relief.”
• This relief decreases as the % dot coverage increases, and is sufficient to confine ink to the dot surface.
• Halftone relief is controlled by a number of factors, including the etching process used to remove the material from between the dots.
• a photopolymer flexographic printing plate the maximum relief depth is controlled by a back exposure of the plate which hardens the photopolymer to a desired depth and establishes a floor and thus a maximum relief depth.
• AM amplitude modulated screening
• a 98% dot means that 98% of a given area is occupied by the dot surface size.
• a 2% dot means that 2% of the same given area is occupied by the dot surface area therein.
• FM frequency modulated
• the shape of the dots and the depth of the relief affect the quality of the printed image. It is very difficult to print small graphic elements such as fine dots, lines and even text using flexographic printing plates while maintaining open reverse text and shadows, hi the lightest areas of the image (commonly referred to as highlights) the density of the image is represented by the total area of dots in a halftone screen representation of a continuous tone image.
• SK is sometimes higher at tone levels less than 100%, e.g., the optical print density achieved at the 97% tone level is sliglitly higher than that achieved at a 100% (solid) tone.
• DigiCap available from Kodak
• Groovey Screens available from Esko-Graphics. DigiCap applies a user definable texture pattern to the surface of a flexographic printing plate to improve ink transfer and the appearance of solid areas, especially when printing on high hold-out substrates such as film or coated paper stocks.
• Groovy Screens a hybrid screening technology, uses traditional AM screening throughout most of an image, but adds a line pattern (or "grooves") into the dark, shadow areas and solids.
• the transition between the normal screen pattern and the line pattern is gradual, leading to a smooth gradation in print between the lower density of the non-groovy print (highlights and midtones) and the higher density (shadows) of the groovy print.
• these techniques often require considerable experimentation and fine control to achieve consistent success, and can also have negative interactions (e.g., moire) with the graphic images being printed. Maintaining small dots on flexographic plates can be very difficult due to the nature of the platemaking process.
• Photocurabie resin compositions typically cure through radical polymerization, upon exposure to actinic radiation.
• the curing reaction can be inhibited by molecular oxygen, which is typically dissolved in the resin compositions, because the oxygen functions as a radical scavenger. It is therefore desirable for the dissolved oxygen to be removed from the resin composition before image-wise exposure so that the photocurabie resin composition can be more rapidly and uniformly cured and to improve the overall plate structure.
• the present invention relates generally to a method of making a relief image printing element having a relief pattern comprising a plurality of relief dots, wherein the pliotocurable printing element comprises a backing layer having at least one photocurable layer disposed thereon and a laser ablatable masking layer on the at least one photocurable layer, the method comprising the steps of:
• a problem in printing solid areas in flexography is uneven ink transfer over the full solid area, lack of density and a halo effect along the edges of the solid area.
• the present invention relates generally to a method of making a relief image printing element having a relief pattern comprising a plurality of relief dots, wherein the photocurable printing element comprises a backing layer having at least one photocurable layer disposed thereon and a laser ablatable masking layer on the at least one photocurable layer, the method comprising the steps of:
• the step of developing the printing blank by removing the barrier layer and the uncured portions of the photocurable layer is typically accomplished by a method selected from the group consisting of water development, solvent development and thermal development. Depending upon the construction of the barrier layer, it is either peeled away or dissolved in the process.
• the present invention alleviates the problems of the prior art by improving the ink carrying ability of the solid areas of the flexo graphic, printing plates by providing in that surface a textured surface, which, in a preferred embodiment, comprises a plurality of cells.
• the sub-image within the overall image creates this texture on the surface of the photopolymerizable layer in a pattern of cells.
• the process of the present invention also produces halftones, particularly halftones present together with solids, by providing a textured surface comprising cells in selected halftone dots. In one embodiment, at least one of halftone dots has a cell on a surface thereof.
• the sub-image which will create the texture and cells on the surface of the photopolymer is created by ablating a pattern into the overall image such that the pattern is on a smaller scale than the overall image features so that the sub-image pattern is fully contained within the overall image features.
• the sub-irnage can be present throughout the entire overall image or only portions thereof.
• the pattern of the sub-image can take a variety of shapes such as circles, polygons or lines.
• a commercial process which is capable of creating this sub-image with a repeating pattern is sold by Esko Corporation of Ghent, Belgium under the trademark, MICROCELLTM.
• the cells are centered in the halftone dots, and are smaller than the halftone dot on which they reside, to avoid creating a cell that extends past an edge of a halftone dot thereby creating scalloped or incomplete halftone dots.
• more than one cell may be placed thereon. In such case, the cells placed within the halftone dot during the creation of the screen film intermediate may be centered around the dot center.
• the dots eventually contact and blend with each other so that after a 50% coverage is reached one no longer has isolated relief areas per dot, but instead isolated holes are observed separating the dots, extending from the surface of the plate toward the floor.
• the cells become smaller and smaller and progressively less deep.
• the depth of the hole is dependent on the dot separation (or the diameter of the hole).
• Upper limits of flexographic printing plates are 95% dot coverage before plugging of the holes occurs, and possibly even 98% before plugging of the holes occurs. This effect is used in the present invention to create a plurality of shallow cells in the surface of solid and halftone dot areas in a flexographic plate to improve printing quality.
• the halftone dot pattern in flexographic plates is of the order of a 100 to 150 lines per inch (Ipi) while the cells are arrayed at considerably higher frequencies of 500 to 1000 lpi.
• the cells appear to behave as anchor points for the ink film on the plate creating an even ink distribution over the solid surface area and then aiding in the uniform transfer of the ink film from the plate to the substrate after impression.
• Printing of solids is thus very uniform and has good saturation and density, exceeding the saturation and density obtained by the traditional smooth solid printing surface used heretofore.
• the inventors of the present invention have found that removal of dissolved oxygen from photociirabie layers may surprisingly also improve imaging fidelity and provide significant improvements in the achievable SID, especially when used in combination with surface patterning techniques described herein.
• oxygen barrier membranes are clear films that minimize light scattering.
• oxygen barrier membranes include materials that are conventionally used as release layers in flexographic printing elements, including polyamides, polyvinyl alcohol, hydroxyalkyl cel lulose, polyvinyl pyrrolidinone, copolymers of ethylene and vinyl acetate, amphoteric ⁇ , cellulose acetate butyrate, alky! cellulose, butyral, cyclic rubbers, and combinations of one or more of the foregoing.
• films such as polypropylene, polyethylene, polyvinyl chloride, polyester and similar clear films can also serve well as barrier films.
• the barrier membrane comprises a polypropylene film or a polyethylene terephthalate film.
• barrier layer is a liquid or non-oxygen gas barrier in which the printing plate may be covered with a layer of liquid or non oxygen gas, such as a layer of oil, prior to the exposure step, and the oil may be either clear or tinted.
• the liquid or non-oxygen gas here serves as another form of a barrier layer.
• the liquid or non-oxygen gas used be optically transparent to the actinic radiation used to expose the photocurable layer.
• Three qualities that the inventors have identified in producing effective barrier layers include optical transparency, low thickness and oxygen transport inhibition.
• the barrier membrane needs to have a sufficient optical transparency so that the barrier will not detrimentally absorb or deflect the actinic radiation used to expose the photosensitive printing blank.
• the barrier membrane have an optical transparency of at least 50%, most preferably at least 75%.
• Oxygen transport inhibition is measure in terms of a low oxygen diffusion coefficient.
• the oxygen diffusion coefficient of the membrane (or the liquid layer) should be less than 6.9 xl(P mVsec, preferably less than 6.9 x10 -10 m 2 /sec. and most preferably less than 6.9 x 10 -l ! m 2 /sec. in the case of the oxygen barrier membrane, the barrier membrane thickness should be consistent with the structural needs for handling of the film and the film/photopolymer plate combination. Barrier membrane thicknesses between about 5 and 300 microns are preferred, more preferably between about 10 and about 200, and most preferably between about 1 and 20 microns.
• the barrier membrane needs to be sufficiently impermeable to oxygen diffusion so that it can effectively limit diffusion of oxygen into the photocurable layer during exposure to actinic radiation.
• the inventors herein have determined that the barrier membrane materials noted above in the thicknesses noted above will substantially limit the diffusion of oxygen into the photocurable layer when used as described herein.
• the barrier layer may be laminated to the surface of the printing plate using pressure and/or heat in a typical lamination process.
• the liquid in the case of the liquid, barrier layer, a liquid layer from ⁇ to ⁇ in thickness comprising any of the following oils will meet the foregoing criteria: paraffimc or naphthenic hydro-carbon oils, silicone oils and vegetable based oils, in a preferred embodiment, the liquid should be spread upon the surface of the printing element before the printing blank is exposed to actinic radiation. The liquid must also be viscous enough to remain in place during processing. Finally, the relief image printing element is mounted on a printing cylinder of a printing press and printing is commenced.
• Another advantage to reducing the impact of oxygen inhibition during plate exposure is that printing dots can be produced having a particular set of geometric characteristics that further contribute to superior printing performance.
• dots are formed without the restricting effect of oxygen inhibition, resulting in flat tops and steep shoulder angles, the curing rate is controlled to the point that optimum reverse depths are maintained and should angles are not excessively broadened, and the resulting membrane lamination minimizes the creation of excessive surface roughness during thermal processing.
• the screened film intermediate is placed on or brought into contact with the oxygen barrier layer on top of the photopolymenzable plate and the plate is exposed through the screen film intermediate and the oxygen barrier layer to UV radiation.
• the polymer material under the film dots remains unpolymerized.
• the platejsurface bears in the solid image areas a plurality of shallow cells having a typical depth of about 15 microns.
• a number of halftone dots in the selected % dot sizes similarly bear on their surface shallow cells. In one embodiment these cells are centered in the halftone dots.
• the depth of the ink cells in the half tone dots is controlled in the same manner as the depth of the ink cells in the solids.
• the halftone dots themselves are processed to a depth which ideally approaches the plate floor. The halftone dot relief in every case is enough so that upon inking of the plate with the anilox roil, only the top surface area of the halftone dot and the ink cell, where there are ink cells, retain ink.
• a print trial was conducted in which Digital MAX 0,067'7L70 mm plates (available from MacDermid Printing Solutions) were imaged on an Esko Advance imager (available from EskoArtworks) with HlghRes optics and HI) Flexo 2.0 software package (available from EskoArtworks).
• An oxygen barrier membrane (Membrane 100, available from MacDenrdd Printing Solutions) was laminated to the Digital MAX plate using MacDermid Printing Solution's LUX laminator.
• test image incorporated 32 separate MicroCell patterns in 4x5 cm patches, along with a control solid patch with no screening applied. Plates were printed with 1320 stickyback, which is a standard choice for hard digital plate.
• the substrate printed was opaque white polyethylene, using Sun Chemical's solvent- based cyan ink on an Avanti 8 color CI press (available from PCMC).
• Anilox rolls (available from Harper Corp., Charlotte, NC) were used having 800 lines per inch (Ipi) with a cell volume of 2.0 bcm (billion cubic microns per square inch) (cell volume refers to the ink cajTying capacity of a cell multiplied by the number of cells in a given square inch of roll surface).
• Readings of each screening condition were taken as averages of three separate print repeats, repeats collected after an X minute run-in period for each plate. in order to evaluate the effect on solid ink density of various MicroCeli patterns, 32 separate MicroCeli patterns were print tested in order to allow for compaiison of both an oxygen barrier membrane coated plate versus standard performance for a given MicroCeli variant and to determine which variant offered the highest possible SID overall.
• the standard Digital MAX plate solid produced a SID of 1.26, while the oxygen barrier membrane coated Digital MAX plate gave a reading of 1.30.
• the 0.04 density difference is not statistically significant, nor is it large enough to be visually detectable. From this, it was concluded that the oxygen barrier membrane did not, by itself improve the SID of solid print performance of the Digital MAX plate.
• the oxygen barrier membrane raised the maximum SID achievable from 1.61 to 1.76, which represents a 9% increase over the best SID achieved without the oxygen barrier membrane and a 35% SID increase compared to the control solid.
• Fully 9 of the MicroCell-oxygen barrier membrane variants gave a higher SID than the maximum achieved by the best MicroCeil variant in standard digital plate format.
• four of the MicroCeil variants that gave lower SID than the control in standard digital plates improved drastically, yielding much higher SID than the control once treated with the oxygen barrier membrane.
• Both solid and halftone areas hi printed images that were printed with plates produced according to this invention exhibit higher density, better color uniformity and a reduction in halo around the edges of solids, than plates printed with the traditional smooth (no ink cells) area surface, in addition, the combination of the screened microcells with the use of the oxygen barrier membrane, improved ink lay-down and increased ink density on the final print,

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